Laser Spot Welding with Real-Time Surface State Feedback
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Solution Overview
Problem
Existing spot welding processes using laser beams face challenges in maintaining consistent weld quality due to unpredictable variations in the original surface state of materials, leading to inconsistent results across different samples.
Innovation Solution
A welding process that involves directing a laser beam onto the weld region, measuring characteristic physical parameters, and adjusting the laser beam characteristics in real-time to adapt to the surface state evolution, ensuring consistent weld quality by monitoring and controlling the dimensions of spot welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If fixed welding parameters are used based on database signatures, then welding process simplicity is maintained, but weld quality consistency deteriorates due to unpredictable surface state variations
Solution Approach 1:
The patent implements real-time feedback by measuring physical parameters (such as reflected energy, transmitted energy, or surface temperature) during the welding process and using these measurements to dynamically adjust welding parameters. This closed-loop control system continuously adapts to surface state variations, ensuring consistent weld quality without requiring complex pre-programmed parameter sets for every possible surface condition.
Solution Approach 2:
The patent transitions from static, pre-determined welding parameters to dynamic parameter adjustment. The welding parameters (such as power, pulse duration, or focal position) are modified in real-time based on measured surface state evolution, allowing the system to adapt to unpredictable variations in material surface conditions while maintaining process simplicity through automated control.
2Manufacturing precision
If welding parameters are adjusted to accommodate surface variations, then weld quality consistency improves, but process complexity increases
Solution Approach 1:
The patent enables the welding system to self-adjust by automatically measuring surface state parameters and modifying welding parameters without external intervention. The system performs its own diagnostics and corrections in real-time, reducing the need for complex external control systems or manual adjustments while maintaining high weld quality consistency.
Solution Approach 2:
The patent replaces complex mechanical adjustment mechanisms with automated optical or sensor-based measurement and control systems. Instead of requiring manual intervention or complex mechanical parameter adjustment devices, the system uses non-contact measurement techniques (such as optical sensors measuring reflected or transmitted energy) to detect surface state and automatically controls welding parameters through electronic systems.
3Reliability
If real-time monitoring and adjustment is implemented, then weld quality and reproducibility improve, but measurement and control requirements increase
Solution Approach 1:
The patent implements partial monitoring by focusing measurement efforts on the most critical parameters that have the greatest impact on weld quality. Rather than attempting to measure and control all possible surface state variables, the system identifies and monitors key parameters (such as reflected energy or surface temperature) that provide sufficient information for effective real-time adjustment, thereby reducing measurement complexity while maintaining high reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables effective monitoring and adaptation of the welding process, achieving good reproducibility and improved quality of welds by fine-tuning the laser beam parameters based on real-time surface state feedback, particularly effective for difficult-to-weld metals like copper.
Implementation Method 1
directing a laser beam onto the weld region of the material to be welded
Implementation Method 2
the surface of the material undergoes physical transformations during welding
Implementation Method 3
measuring and analysing the values of various physical parameters that change as welding progresses, namely the energy reflected by the surface of the material
Implementation Method 4
the energy transmitted through the material
Data Source
AI summary
The invention relates to a laser spot welding process for executing a spot weld in two successive steps, namely a first step of preparing the surface state of the material to be welded and a second step of welding as such. The luminous energy (BR) reflected by the weld region of the material is measured in real time during the first step and then processed by a controller circuit (37) connected to a control circuit (30) of the laser source (31). In this way, the characteristics (LM) of the laser beam are adjusted in real time as a function of the measurements effected to allow effective control of the quality of the weld obtained, and in particular of its dimensions.The invention also relates to a welding device for implementing this process.